Section 6 (Automatic Transmission - 5R110W): Assembly: Transmission: Assembly

WARNING: This page is about a different variant/trim than selected.

NOTE: Soak all friction clutch plates in clean automatic transmission fluid.

NOTE: Prior to installation, lightly lubricate all O-ring seals with clean automatic transmission fluid.

NOTE: Lightly lubricate all thrust washers with petroleum jelly to hold them in place during assembly.

NOTE: Late production transmission cases have a wider groove for the low/reverse snap ring. Early production cases can be identified by a large, round boss on top of the bell housing with a hole drilled in it for a wiring clip. Late production cases have this bell housing boss without the drilled hole.

All transmissions

Mount the transmission case onto a suitable stand.
If removed, use the special tool to install the short fluid inlet tube.

Fig 1: Installing Short Fluid Inlet Tube
Courtesy of FORD MOTOR CO.
If removed, use the special tool to install a new Teflon® seal retainer.
- Install 2 new Teflon® seals.
Fig 2: Installing New Teflon Seals
Courtesy of FORD MOTOR CO.

NOTE: Coat the reverse clutch piston seals with petroleum jelly.

Fig 3: Installing Reverse Clutch Piston In Case

Courtesy of FORD MOTOR CO.

Install the reverse clutch piston in the case until it is fully seated in the case.
Install the reverse clutch return spring assembly.

Fig 4: Installing Reverse Clutch Return Spring Assembly
Courtesy of FORD MOTOR CO.

WARNING: Do not over compress the return spring, or damage to the spring will occur.

Fig 5: Installing Reverse Clutch Return Spring Snap Ring

Courtesy of FORD MOTOR CO.

Using the special tools, install the reverse clutch return spring snap ring.

NOTE: The use of petroleum jelly will hold the No. 17 thrust bearing or washer in place during assembly.

Fig 6: Identifying Park Gear Thrust Washer

Courtesy of FORD MOTOR CO.

For vehicles equipped with a slip yoke, install the No. 17 park gear thrust bearing. For vehicles equipped with a fixed yoke, install the No. 17 park gear thrust washer.

WARNING: Be careful when installing the output shaft not to damage the seals or a transmission leak could occur.

Fig 7: Installing The Output Shaft

Courtesy of FORD MOTOR CO.

Install the output shaft.

CAUTION: The Torx® screw has a threadlocking compound. If the screw is removed, it must be discarded and a new screw installed.

Fig 8: Installing Parking Pawl Abutment With A New Torx® Screw With Torque Specification

Courtesy of FORD MOTOR CO.

If removed, install the parking pawl abutment with a new Torx® screw.
Install the parking pawl.
1. Install the parking pawl shaft.
2. Install the parking pawl.
3. Install the parking pawl return spring.
  
  Fig 9: Installing Parking Pawl Return Spring
  Courtesy of FORD MOTOR CO.

NOTE: Make sure the dimple on the parking guide support plate is facing inward.

Install the parking rod guide plate.
1. Install the parking rod guide plate.
2. Install the bolts.
  
  Fig 10: Installing Parking Rod Guide Plate With Torque Specification
  Courtesy of FORD MOTOR CO.
Install a new orifice lube plug in the rear of the case. Using a 12 mm (0.48 in) socket, tap the orifice lube plug into the back of the transmission. Check to make sure that the orifice lube plug is fully seated into the back of the transmission.

Fig 11: Installing A New Orifice Lube Plug In The Rear Of The Case
Courtesy of FORD MOTOR CO.
Install a new extension housing gasket.

Fig 12: Identifying Extension Housing Gasket
Courtesy of FORD MOTOR CO.
Install the extension housing.

Fig 13: Extension Housing Bolts With Torque Specification
Courtesy of FORD MOTOR CO.
Using the special tool, install a new manual control lever seal.

Fig 14: Installing A New Manual Control Lever Seal
Courtesy of FORD MOTOR CO.
Install the transmission range (TR) sensor, park rod assembly and loosely install the bolts.

Fig 15: Installing Transmission Range (TR) Sensor Park Rod Assembly
Courtesy of FORD MOTOR CO.
Install the manual control lever.

Fig 16: Installing Manual Control Lever
Courtesy of FORD MOTOR CO.
Install the roll pin into the case.

Fig 17: Installing Roll Pin Into Case
Courtesy of FORD MOTOR CO.
Install a new roll pin. Leave 2 mm (0.08 in) of the pin exposed.

Fig 18: Installing New Roll Pin Exposed
Courtesy of FORD MOTOR CO.
Tighten the TR sensor bolts.

Fig 19: Tightening TR Sensor Bolts With Torque Specification
Courtesy of FORD MOTOR CO.

Fixed yoke transmissions

Using the special tool, install a new extension housing seal.

Fig 20: Using The Special Tool, Install A New Extension Housing Seal
Courtesy of FORD MOTOR CO.
Inspect the new output shaft nut O-ring for cuts. A new nut must be installed.

Fig 21: Inspecting New Output Shaft Nut O-Ring For Cuts
Courtesy of FORD MOTOR CO.
Using the special tool, install the output shaft nut.

Fig 22: Installing Output Shaft Nut With Torque Specification
Courtesy of FORD MOTOR CO.
Install the output flange and a new bolt.
1. Install the flange.
2. Install a new bolt.
  
  Fig 23: Installing Output Shaft Flange With Torque Specification
  Courtesy of FORD MOTOR CO.

Slip yoke transmissions

Install a new extension housing seal using the special tool.

Fig 24: Installing A New Extension Housing Seal
Courtesy of FORD MOTOR CO.

NOTE: The No. 13 and the No. 14 thrust washer should be attached to the carrier during installation.

All transmissions

Install the No. 16 bearing and race.

Fig 25: Installing Bearing And Race
Courtesy of FORD MOTOR CO.
Install the ring gear, hub and the No. 15 hub bearing.

Fig 26: Installing Ring Gear Hub And Hub Bearing
Courtesy of FORD MOTOR CO.
Install the reverse carrier and hub assembly.

Fig 27: Installing Reverse Carrier And Hub Assembly
Courtesy of FORD MOTOR CO.
Install the reverse clutch plates.
- Install the separator plate, alternating between the steel and friction plates. Install a steel plate then a friction plate, then install the OWC.
- If the OWC is installed correctly, it should hold when trying to turn it counterclockwise and turn freely when turning it clockwise.
Fig 28: Installing Reverse Clutch Plates (1 Of 3)
Courtesy of FORD MOTOR CO.

Early production vehicles with an early production case (low/reverse clutch parts)

Fig 29: Installing Reverse Clutch Plates (2 Of 3)
Courtesy of FORD MOTOR CO.

Early production vehicles with a late production case (low/reverse clutch parts)

Fig 30: Installing Reverse Clutch Plates (3 Of 3)
Courtesy of FORD MOTOR CO.

All transmissions

CAUTION: Do not exceed 138 kPa (20 psi) when applying air pressure to the low reverse clutch port.

CAUTION: Do not apply air pressure to move the low/reverse piston without first installing the friction plates and the case snap ring, or damage to the spring retainer snap ring will occur.

NOTE: If the early production case is damaged, a late production case must be used along with a 2-tang, thick, flat low/reverse-to-case snap ring oriented as shown.

Fig 31: Checking Function Of Reverse Clutch

Courtesy of FORD MOTOR CO.

Install the new snap ring and make sure that the snap ring is fully seated in the case groove. The gap of the retaining ring should be in the 1 o'clock position.
Install a new flat snap ring so the tang ends are in the gaps to the right and to the left of the case spline as shown.
- Check the function of the reverse clutch by applying 138 kPa (20 psi) air to the correct passage (through the case valve body worm trail) for the reverse clutch.
For early production vehicles, use the special tools and install the forward geartrain as an assembly.

Fig 32: Installing Forward Geartrain As An Assembly
Courtesy of FORD MOTOR CO.
For late production vehicles, use the special tools and install the forward geartrain as an assembly.

Fig 33: Installing Forward Geartrain As An Assembly
Courtesy of FORD MOTOR CO.
Install the intermediate clutch pressure plate.
- Position the intermediate clutch pressure plate in the case with the 3 tabs facing downward.
Fig 34: Installing Intermediate Clutch Pressure Plate
Courtesy of FORD MOTOR CO.

Inspect the intermediate clutch friction plates.

For early production transmission, the intermediate clutch friction plates have 24 internal teeth and use 3.18 mm (0.12 in) thick steel plates.
For late production transmission, the intermediate clutch friction plates have 96 internal teeth and use 2.98 mm (0.11 in) thick steel plates.

2005 EARLY PRODUCTION 3 PLATE CLUTCH

Install new parts with 2005 late production pressure plate and separator plates as a set.
Intermediate Clutch Separator Plates	Intermediate Clutch Separator Plates
3.18 mm (0.12 in) thick	13.31 mm (0.52 in) thick with two ID grooves on teeth

2005 LATE PRODUCTION 3 PLATE CLUTCH

Install new parts with 2005 late production pressure plate and separator plates as a set.
Intermediate Clutch Separator Plates	Intermediate Clutch Separator Plates
2.98 mm (0.11 in) thick	13.92 mm (0.55 in) thick with two ID grooves on teeth

Fig 35: Inspecting Intermediate Clutch Friction Plates

Courtesy of FORD MOTOR CO.

Install the intermediate clutch plates, starting with a friction plate.

Fig 36: Installing Intermediate Clutch Plates Starting With A Friction Plate
Courtesy of FORD MOTOR CO.
Install the center support.

Fig 37: Installing Center Support
Courtesy of FORD MOTOR CO.

NOTE: The snap ring should be installed with the flat edge facing downward. The gap in the snap ring should be facing in the 6 o'clock position. Tap the snap ring securely into the case.

Using the special tool, install the center support snap ring.
1. Retaining ring.
2. Center support.
3. Transmission case.
  
  Fig 38: Installing Center Support Snap Ring
  Courtesy of FORD MOTOR CO.
For the early production vehicles, loosely install the forward clutch and the intermediate clutch feed bolts.

Fig 39: Installing Forward Clutch And Intermediate Clutch Feed Bolts
Courtesy of FORD MOTOR CO.
For the late production vehicles, loosely install the feed bolts.
1. Loosely install the Torx® forward clutch feed bolt into the case toward the rear of the case.
2. Loosely install the hex head intermediate clutch feed bolt into the case toward the front of the case.
  
  Fig 40: Installing Hex Head Intermediate Clutch Feed Bolt Into Case Toward Front Of Case
  Courtesy of FORD MOTOR CO.
For early production vehicles, tighten the feed bolts.

Fig 41: Tightening Feed Bolts With Torque Specification (Early Production Vehicles)
Courtesy of FORD MOTOR CO.
For late production vehicles, tighten the feed bolts.
1. Tighten the Torx® forward clutch feed bolt.
2. Tighten the hex head intermediate clutch feed bolt.
  
  Fig 42: Tightening Hex Head Intermediate Clutch Feed Bolt With Torque Specification (Late Production Vehicles)
  Courtesy of FORD MOTOR CO.
Install the No. 5 thrust bearing onto the center support.

Fig 43: Installing Thrust Bearing Onto Center Support
Courtesy of FORD MOTOR CO.
Install the center shaft and ring gear.

Fig 44: Installing Center Shaft And Ring Gear
Courtesy of FORD MOTOR CO.
Install the No. 4 thrust bearing onto the center shaft.

Fig 45: Installing Thrust Bearing Onto Center Shaft
Courtesy of FORD MOTOR CO.
Using the special tool, install the coast clutch assembly and overdrive carrier.

Fig 46: Installing Coast Clutch Assembly And Overdrive Carrier
Courtesy of FORD MOTOR CO.
Install the overdrive clutch assembly snap ring with the gap in the 6 o'clock position.

Fig 47: Installing Overdrive Clutch Assembly
Courtesy of FORD MOTOR CO.
Install the overdrive pressure plate with the notches facing up.

Fig 48: Installing Overdrive Pressure Plate With Notches Facing Up
Courtesy of FORD MOTOR CO.
Install the overdrive clutch.
- Start with a friction plate, alternating with a steel plate.
Fig 49: Installing Overdrive Clutch
Courtesy of FORD MOTOR CO.
Check that the No. 2 and No. 1 thrust bearings are on the pump.

Fig 50: Checking Thrust Bearings Are On Pump
Courtesy of FORD MOTOR CO.
Install a new pump gasket.

Fig 51: Installing A New Pump Gasket
Courtesy of FORD MOTOR CO.
Install a new stator support seal onto the pump and install the input shaft into the case.

Fig 52: Installing A New Stator Support Seal Onto Pump
Courtesy of FORD MOTOR CO.

NOTE: Alignment pins are used in case holes located at the 5 o'clock and 11 o'clock positions.

Fig 53: Installing Special Tools Into Case Pump

Courtesy of FORD MOTOR CO.

Install the special tools into the case in order to install the pump.

NOTE: Pump-to-case alignment pins are used in case holes located at the 11 o'clock and 5 o'clock positions.

Fig 54: Installing Pump Assembly

Courtesy of FORD MOTOR CO.

Using the special tools, install the pump assembly.
Install new retaining bolts.

Fig 55: Installing New Retaining Bolts With Torque Specification
Courtesy of FORD MOTOR CO.
Install a new main control body gasket.

Fig 56: Installing A New Main Control Body Gasket
Courtesy of FORD MOTOR CO.
Using the special tools, check the function of each clutch. Apply 137.9 kPa (20 psi) of air to each port.

Fig 57: Checking Function Of Each Clutch
Courtesy of FORD MOTOR CO.
For early production vehicles, use petroleum jelly to hold the forward clutch feed orifice in place on the top of the forward clutch feed bolt. Install the forward clutch feed orifice.

Fig 58: Installing Forward Clutch Feed Orifice
Courtesy of FORD MOTOR CO.
Using the special tools, install the solenoid body and loosely install the bolts.
- While installing the solenoid body, align the manual valve.
Fig 59: Installing Solenoid Body
Courtesy of FORD MOTOR CO.
Tighten all the bolts in the sequence shown.

Fig 60: Tightening Bolts In Sequence With Torque Specification
Courtesy of FORD MOTOR CO.
Connect the TR sensor connector.

Fig 61: Connecting TR Sensor Connector
Courtesy of FORD MOTOR CO.

NOTE: Prior to installing the fluid filter, make sure that the old seal is not stuck in the case.

Fig 62: Installing New Transmission Fluid Filter

Courtesy of FORD MOTOR CO.

Install a new transmission fluid filter.

NOTE: Reuse the fluid pan gasket unless it is damaged.

Fig 63: Positioning The Gasket Onto The Clean Fluid Pan

Courtesy of FORD MOTOR CO.

Install the transmission fluid pan gasket to the fluid pan. Make sure the magnet is positioned over the dimple in the fluid pan.
Install the transmission fluid pan.

Fig 64: Installing Transmission Fluid Pan With Torque Specification
Courtesy of FORD MOTOR CO.
Install the intermediate shaft and turbine shaft speed (TSS) sensor.

Fig 65: Install The Intermediate Shaft And Turbine Shaft Speed (TSS) Sensor With Torque Specification
Courtesy of FORD MOTOR CO.
Install the output shaft speed (OSS) sensor.

Fig 66: Installing Output Shaft Speed (OSS) Sensor With Torque Specification
Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the fluid pump stator support seal when installing the torque converter.

CAUTION: Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely. Do not damage the hub seal.

CAUTION: If the torque converter slides out, the hub seal may be damaged.

Fig 67: Lubricating Converter Hub With Clean Automatic Transmission Fluid

Courtesy of FORD MOTOR CO.

Lubricate the converter hub with clean automatic transmission fluid.

CAUTION: Use care when installing the torque converter to avoid damage to the front pump stator support seal.

NOTE: Check the converter crankshaft pilot for nicks or damaged surfaces that can cause interference when installing the transmission to the engine. Check the converter impeller hub for nicks or sharp edges that can damage the pump seal.

Fig 68: Installing Torque Converter

Courtesy of FORD MOTOR CO.

Using the special tools, install the torque converter. Push and rotate the converter onto the front pump assembly until it bottoms out.
Check the seating of the torque converter.
1. Place the straightedge across the converter housing.
2. Make sure there is a gap between the converter pilot face and the straightedge.
3. Remove the special tools.
  
  Fig 69: Removing Special Tools
  Courtesy of FORD MOTOR CO.
Use the special tool to hold the torque converter in place when installing the transmission.

Fig 70: Identifying Special Torque Converter Tool
Courtesy of FORD MOTOR CO.